Temp-A-Start Regeneration System

ABSTRACT

A regeneration module is usable in conjunction with a diesel engine to control the operation of a regeneration cycle of the diesel engine. During the regeneration cycle, particulate matter collected in or on a diesel particulate filter of the diesel engine is removed to improve the operation of the diesel particulate filter. In various embodiments, the regeneration module is connected to a remote operator such that the regeneration cycle is activated during desirable idle periods of the diesel engine as determined by the controller.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 13/313,573 filed on Dec. 7, 2011 which claims the benefit of U.S. Patent Application Ser. No. 61/420,612 filed on Dec. 7, 2010.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is related to a system, method, and apparatus for regenerating a particulate filter. This invention is more particularly related to a system, method, and apparatus for regenerating a particulate filter for a heavy duty diesel engine.

2. Related Art

Due, at least in part, to incomplete combustion, diesel engines produce various amounts of particulate matter during operation. This particulate matter may be dangerous to the environment, an operator's health or otherwise undesirable. Additionally, engine exhaust may be regulated by local and/or federal laws such that removal of the particulate matter (e.g., pollutants) may be desirable and/or obligatory.

Removing particulate matter from engine exhaust often involves the use of filters such as a diesel particulate filter. In various embodiments, the engine exhaust is forced through the diesel particulate filter depositing at least some of the particulate matter on or in the diesel particulate filter. Over time, particulate matter collects on the filter and the filter may become less effective (e.g., by restricting flow of the engine exhaust, reducing fuel economy, and/or by reducing the amount of particulate matter that is removed from the engine exhaust). As such, various types of diesel particulate filters are designed to be replaced and/or regenerated. Failing to replace and/or regenerate a diesel particulate filter may have an adverse effect on engine performance, engine life expectancy, and/or other factors related to the operation of the diesel engine.

BRIEF DESCRIPTION OF DRAWINGS

Various exemplary embodiments of the systems and methods according to this invention will be described in detail, with reference to the following figures, wherein:

FIG. 1 illustrates exemplary methods of connecting a regeneration module to an engine controller such as an engine control module;

FIG. 2 illustrates an exemplary schematic of a regeneration module; and

FIG. 3 is a flow chart illustrating an exemplary method of regenerating a particulate filter.

DETAILED DESCRIPTION OF DISCLOSED EMBODIMENTS

Regenerating a diesel particulate filter removes accumulated particulate matter (e.g., soot) from the filter to improve the operation of the diesel particulate filter (e.g., by reducing the pressure drop across the filter, improving the efficiency of the filter, etc.). Typically, the particulate matter is removed by increasing the temperature of the diesel particulate filter and/or the engine exhaust to a temperature sufficiently high enough to cause the particulate matter to combust (e.g., burn off).

It should be appreciated that the temperature required to combust the particulate matter will vary depending on the chemical composition of that particulate matter, which itself may be dependent on the chemical composition of the fuel used, additional additives combined with the fuel and/or exhaust gas, and/or the composition of the diesel particulate filter. In various embodiments, it may be desirable to decrease the combustion temperature below a critical threshold (e.g., the temperature at which the diesel particulate filter may be compromised).

FIG. 1, illustrates exemplary methods of connecting a regeneration module to an engine controller. As shown in FIG. 1, the regeneration module may be connected to either a high side driver or a low side driver of an engine controller (e.g., an engine control module, an engine control unit, an electronic control module, and/or the like). The engine controller manages the operation of the engine. In various exemplary embodiments, the engine controller manages various parameters of the engine, which may be a diesel engine, such as, for example, rate of fuel flow, ignition timing, and air intake. The engine controller may also communicate with various sensors that monitor various parameters of the engine, such as, for example, exhaust temperature, engine temperature, engine speed, and/or any other desirable engine parameter.

In various exemplary embodiments, if the engine controller utilizes a low side driver, a diode kit is provided between the regeneration module and the engine controller to prevent damage to any other devices previously connected to the engine controller. The diode kit may include, for example, a diode, one or more resistors and/or any other desirable electrical component(s). The regeneration module is also connected to an indicator, such as a light emitting diode (LED) or the like, to indicate whether the regeneration module is operating. In various exemplary embodiments, a red LED indicates that the regeneration module is active but not operating (e.g., in a standby mode). In various exemplary embodiments, a green LED indicates that the regeneration module is active and operating (e.g., a regeneration cycle is operating).

The regeneration module is designed to operate with a diesel engine to automatically regenerate a diesel particulate filter only when the diesel engine is idling. Additionally, the regeneration module may operate when selected by a user operated switch. Alternatively, the regeneration module may be remotely controlled by a user. In various exemplary embodiments, an operator of a diesel engine, such as, for example a truck driver, may engage the regeneration module by activating a switch in a cab of the truck before leaving the truck unattended. In various other exemplary embodiments, the regeneration module may be activated by a remote user. For example, in various exemplary embodiments, the regeneration module includes a wireless data connection, such as, for example, a cellular modem, a radio transceiver, a phone pager, a satellite receiver or any other known or later developed wireless communication device. In such exemplary embodiments, the regeneration module communicates with a controller operated by a remote user. In one such exemplary embodiment, the regeneration module is connected to a controller, such as, for example, a home terminal at a remote location. In such exemplary embodiments, a user may be able to remotely activate and deactivate the regeneration module, start and stop regeneration cycles, and/or control other aspects of the vehicle, such as, for example, remotely starting or remotely shutting down the vehicle.

It should be appreciated that in various exemplary embodiments, the above-outlined wireless communications devices may be replaced with one or more wired connections. For example, in various exemplary embodiments, a truck that includes a regeneration module is parked at a maintenance location and then connected to one or more wired connections. In various such exemplary embodiments, the regeneration cycles of the truck can then be controlled by an operator through the one or more wired connections.

When engaged, the regeneration module interrupts a regeneration cycle of the engine controller for various time periods. By remotely controlling the regeneration module, a user can ensure that the regeneration module is not currently interrupting normal operations of the vehicle when another user intends to operate the vehicle. For example, in an exemplary embodiment, the regeneration module is controlled by a dispatcher who coordinates the operation of several trucks and truck drivers. By remotely controlling the regeneration module, the dispatcher can determine when to start and/or stop regeneration cycles based on the expected or intended use of the trucks. As such, the dispatcher can ensure that a particular truck is ready to operate when a truck driver arrives to drive the truck. In this manner, the dispatcher may be able to reduce the time that a truck is not able to be operated, e.g., the down time of the truck, due to regular maintenance, such as expected regeneration cycles.

FIG. 2 shows an exemplary schematic of a regeneration module. As shown in FIG. 2, the regeneration module is connected to an engine controller of a diesel engine. As outlined above, the regeneration module may be connected to either a high side or a low side driver of the engine controller. A request is received by the regeneration module (either via the “high side driver signal in” or the “low side driver signal in”) indicating that the engine controller can initiate a regeneration cycle. As shown in FIG. 2, the high side driver signal and the low side driver signal are electronically isolated via one or more diodes. The regeneration module processes the signal received from the engine controller and controls an idle state of the diesel engine (e.g., by turning off a high or fast idle state). The regeneration cycle then activates the regeneration cycle, which is operated by the engine controller. After the regeneration cycle is completed, the regeneration module returns the engine to the high or fast idle state.

It should be appreciated that, in various exemplary embodiments, the regeneration module is connected to the engine controller in a manner that allows the regeneration module to monitor and/or control various engine parameters and functions. For example, in exemplary embodiments that are accessible by a remote user, the remote user may be able to remotely monitor engine performance, engine conditions, start or stop the engine, determine whether the engine needs to be serviced, and/or engage, disengage, start, and/or stop the regeneration module and regeneration cycle.

It should also be appreciated that the schematic shown in FIG. 2 is exemplary. In various embodiments, the operation of the regeneration module may be achieved via one or more integrated circuits, discrete electrical components and/or any other suitable known or later developed compatible electrical circuit.

FIG. 3 shows an exemplary embodiment of a method of operation of a regeneration module (e.g., a stationary regeneration cycle). As shown in FIG. 3, the stationary regeneration cycle begins when the regeneration module receives a request for a regeneration cycle. It should be appreciated that in various exemplary embodiments the regeneration module may only receive a stationary regeneration cycle if a manual switch, for example a switch located in the cab of a diesel engine, has been turned on (e.g., closed) by an operator of the diesel engine. In such exemplary embodiments, the operator has control over whether a stationary regeneration cycle will be executed. Likewise, in various other exemplary embodiments, a remote user can control the regeneration module and dictate whether a stationary regeneration cycle will be executed via the one or more wired or wireless connections outlined above. In various exemplary embodiments, the regeneration module receives the request from an engine controller of the diesel engine, such as, for example, an engine control unit, an engine control module, an electronic control unit, or the like. In various ones of these exemplary embodiments, the engine controller sends the request to the regeneration module via a high side driver. In various other ones of these exemplary embodiments, the engine controller sends the request to the regeneration module via a low side driver.

Upon receiving the request, the regeneration module electronically opens a high idle switch, thereby ending a high idle cycle of the diesel engine (e.g., returning the diesel engine to a base idle condition). In various exemplary embodiments, a first time period is begun. In various ones of these exemplary embodiments, the first time period is, for example, a four second time period. After the first time period is concluded, a regeneration toggle is electronically closed for a second time period. In various ones of these exemplary embodiments, the second time period is, for example, a five second time period.

After the second time period has concluded, the engine controller begins a regeneration cycle. During the regeneration cycle, particulate matter collected in a diesel particulate filter is heated to a point of combusting. By combusting the particulate matter, it is removed from the diesel particulate filter thereby returning the particulate filter to a more efficient mode of operation (e.g., decreasing a pressure drop across the filter, improving the efficiency at which particulate matter is collected by the diesel particulate filter, and/or improving any other parameter of the diesel particulate filter).

It should be appreciated that regenerating the diesel particulate filter may have differing effects on various operating parameters of the diesel particulate filter; each of which may be considered in determining the efficiency of the diesel particulate filter and the current regenerative condition of the diesel particulate filter. For example, a diesel particulate filter may remove more particulate matter before regeneration than after regeneration due to the increased restriction caused by the accumulated particulate matter. However, the increased restriction caused by the accumulated particulate matter may have an undesirable effect on other operating parameters of the diesel particulate filter (e.g., by increasing a pressure drop across the diesel particulate filter). As such, in various exemplary embodiments, while one parameter may indicate an increased efficiency (e.g., a greater amount of particulate matter being removed by the diesel particulate filter), other parameters may indicate that the diesel particulate filter should be desirable regenerated. Likewise, an increase in the amount of particulate matter removed by a diesel particulate filter may indicate that the diesel particulate filter is nearing a point of use indicated by maximum capacity of the diesel particulate filter; at which point it may cease to remove any further particulate matter or otherwise decrease in efficiency.

The engine controller operates the regeneration cycle until conclusion. It should be appreciated that a regeneration cycle may be concluded for any desirable reason. In various exemplary embodiments, the regeneration cycle is concluded after a predetermined time period. In various other exemplary embodiments, the regeneration cycle is concluded when a predetermined amount (e.g., volume) of particulate matter has been removed from the diesel particulate filter. In yet other exemplary embodiments, the regeneration cycle is concluded when the operation of the diesel particulate filter has reached a predetermined level of functionality or efficiency, such as, for example, when a pressure drop across the filter has been reduced to a desirable level.

Likewise, the regeneration cycle may be terminated remotely by a remote user via one or more wired or wireless connections to the regeneration module. For example, in various exemplary embodiments, a dispatcher is connected to a regeneration module of a truck via one or more wired or wireless connections. When the dispatcher assigns the truck for operation (e.g., schedules a truck driver to operate the truck), the dispatcher can remotely terminate the regeneration cycle such that the truck is ready for operation when the truck driver arrives to operate the truck. After the regeneration cycle is concluded, the high idle switch is electronically closed, returning the diesel engine to a high idle state and the method of operation is concluded.

It should be appreciated that the regeneration cycle of the engine controller may utilize any suitable known or later developed method of regeneration. For example, the diesel particulate filter may be heated through an external source, such as, for example, a microwave heater, additives may be introduced to the diesel particulate filter, either directly or at an earlier point in the engine exhaust system (e.g., as a fuel additive or an additive to the exhaust line between the engine and the diesel particulate filter) to decrease the combustion temperature of the particulate matter, or the like. 

1. A method for regenerating a diesel particulate filter comprises: establishing a connection between a regeneration module and a controller via at least one of a wired and a wireless data connection; sending a request from an engine controller of a diesel engine to the regeneration module; putting the diesel engine into a base idle mode of operation; waiting for a first defined time period; closing a regeneration switch; waiting for a second defined time period; initiating a regeneration cycle of the engine controller; receiving a signal from the controller; and putting the diesel engine into a high idle mode of operation.
 2. The method of claim 1, wherein initiating a regeneration cycle of the engine controller comprises heating a diesel particulate filter to at least a first desired temperature.
 3. The method of claim 2, wherein heating a diesel particulate filter comprises heating the diesel particulate filter to at least the first desired temperature for a third defined time period.
 4. The method of claim 1, wherein initiating a regeneration cycle of the engine controller comprises activating an external heating source.
 5. The method of claim 1, further comprising: measuring an operating parameter of a diesel particulate filter; sending the measured operating parameter to the controller; and determining a regeneration status of the diesel particulate filter.
 6. The method of claim 5, further comprising terminating the regeneration cycle of the engine controller when a signal is received from the controller.
 7. The method of claim 6, wherein the controller sends a signal to terminate the regeneration cycle if the diesel particulate filter is determined to be sufficiently regenerated.
 8. The method of claim 5, wherein measuring a regeneration quality of a diesel particulate filter comprises measuring a pressure drop across the diesel particulate filter.
 9. The method of claim 8, wherein determining a regeneration status of the diesel particulate filter comprises comparing the pressure drop across the diesel particulate filter to a desired value.
 10. The method of claim 5, wherein measuring an operating parameter of a diesel particulate filter comprises measuring a mass of the diesel particulate filter.
 11. The method of claim 10, wherein determining a regeneration status of the diesel particulate filter comprises comparing the mass of the diesel particulate filter to a desired value.
 12. The method of claim 5, wherein measuring an operating parameter of a diesel particulate filter comprises measuring an efficiency of filtration of the diesel particulate filter.
 13. The method of claim 12, wherein measuring an efficiency of filtration of the diesel particulate filter comprises comparing an amount of particulate matter in an intake of the diesel particulate filter to an amount of particulate matter in an exhaust from the diesel particulate filter.
 14. The method of claim 13, wherein determining a regeneration status of the diesel particulate filter comprises comparing the ratio of the amount of particulate matter in the exhaust from the diesel particulate filter over the amount of particulate matter in the intake of the diesel particulate filter to a desired value.
 15. A system for regenerating a diesel particulate filter comprises: a diesel engine that utilizes a diesel particulate filter which is usable to remove at least some particulate matter from an exhaust gas of the diesel engine during operation; a regeneration module in communication with the engine controller; and a remote operator in communication with the regeneration module via one or more data connections wherein the remote operator is capable of activating and deactivating the regeneration module; wherein the regeneration module is usable to receive a request from the engine controller to initiate a regeneration cycle of the engine controller; and the regeneration cycle is usable to remove particulate matter from the diesel particulate filter.
 16. The system of claim 15, further comprising: a heater usable to raise the temperature of the diesel particulate filter to at least a first desired temperature.
 17. The system of claim 15, further comprising an injection system usable to inject an additive into at least one of a fuel line, an exhaust line, and the diesel particulate filter.
 18. The system of claim 17, wherein the exhaust line is provided between the diesel engine and the diesel particulate filter.
 19. The system of claim 15, wherein the regeneration module is usable to control one or more parameters of the diesel engine.
 20. The system of claim 19, wherein the regeneration module is in communication with one or more sensor usable to determine at least one operating condition of the diesel particulate filter and wherein the at least one operating condition is usable to determine the condition of regeneration of the diesel particulate filter. 